German Manufacturer Relies on EMAG's Vertical Machines to Produce Complex Auto Parts

Unusually sophisticated components and high-strength materials for high-tech applications are among the machining challenges tackled by the specialists at Bharat Forge Daun. To meet these challenges, the company credits several vertical turning machines from EMAG. which are in operation around the clock, five days a week.

Complexity is a specialty at Bharat Forge Daun -- a manufacturer based in the Eifel region of Germany.



With more than 30 years of experience and technological expertise, BHARAT FORGE DAUN supplies its customers with mechanically processed serial parts, tools, dies and fixtures for the manufacture of chassis and engine components as well as products for the agricultural and construction machinery industry and for railway engineering.

Toolmaking at the company, located near Koblenz, Germany, includes the production and reprocessing of dies for hot-working, using cutting-edge technologies. The in-house fixture construction, including three-dimensional manufacture, provides testing and clamping fixtures for industrial applications.

Four VL 8s from EMAG carry out the rough-machining processes on the component at Bharat Forge Daun.



During mechanical processing, highly complex hybrid parts are made on automated production lines. This means that challenges like difficult surfaces and positional arrangements are common.

"Extreme accuracy requirements in the micrometer range are always part of our work," says Christoph Steffens, Head of Mechanical Engineering at Bharat Forge Daun. "In this context, we monitor the processes very comprehensively, carry out many measurements and even accompany the component development on request -- so that the production of the component runs efficiently. We offer this expertise on the market for sectors such as the automotive industry, general mechanical engineering and the production of agricultural machinery."

Work area of the VL 8 at Bharat Forge Daun



Efficient Machining of Forged Stator Housings

A stator housing used in the hybrid drive of a large German automotive company shows what this means in concrete terms.

Even at first glance, it is clear that its pot-like shape and various geometric details are sophisticated. What's more, the blank is a forged steel component -- a rarity in this field of application. Its material properties are an additional challenge for the southwest German machining experts.

In addition, the client has continuously increased the required quantities over the years (and will continue to do so). So how do you combine accuracy, efficiency and process reliability in this environment? Bharat Forge Daun's answer has a lot to do with EMAG's mechanical engineering components, as the specialists have been relying on EMAG lathes for some time.

Vertical Design with Decisive Advantages

The vertical design of these solutions played an important role in the investment decision. The horizontal machine from another manufacturer had caused some difficulties in the past.

VIDEO: VL 8 Vertical Pick-up Turning Machine

For example, annoying chip clusters regularly formed, which had to be removed manually two to three times per shift. "It was therefore obvious to us that we should carry out these processes in machines with a vertical design, because their unhindered chip flow prevents many disruptions. Our objective was to achieve maximum process reliability," emphasizes Steffens.

The blank for a stator housing is a forged steel component.



The decision in favor of the EMAG machines was also based on existing know-how.

The machine manufacturer used examples from other customers to show how stator machining is carried out in their machines -- with low non-productive times and high-precision handling processes. Integrated automation including a pick-up spindle and lateral conveyor belt ensures fast processes, while the stable base body made of the polymer concrete Mineralit® stands for quality in turning and milling processes.

EMAG Service in Focus

The response time and the expertise of EMAG's service department plays an important role for Bharat Forge Daun.

A regional service technician is always on site within a few hours and solves any problems directly. "The machines are very robust. Nevertheless, this issue is important because we produce five days a week in three-shift operation and so far, we have always been helped with minor faults in record time. For example, with a defective light barrier. The repair has never taken longer than two hours," says Christoph Steffens, who also reports that EMAG has also been on site via remote service.

The circulation belt of the VL machines also serves as a parts store.



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Bharat Forge Daun

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